Wiring board and method for manufacturing the same

ABSTRACT

A wiring board has a first rigid wiring board having an accommodation section, a second rigid wiring board to be accommodated in the accommodation section, and an insulation layer formed on the first rigid wiring board and the second rigid wiring board. Here, a conductor of the first rigid wiring board and a conductor of the second rigid wiring board are electrically connected to each other, and at least either a side surface of the second rigid wiring board or a wall surface of the accommodation section has a concave-convex portion.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims the benefits of priority to U.S.Application No. 61/228,286, filed Jul. 24, 2009. The contents of thatapplication are incorporated herein by reference in their entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a wiring board and its manufacturingmethod.

2. Discussion of the Background

In Japanese Laid-Open Patent Publication 2003-298234, a wiring board isdescribed which is formed with a first wiring board having a firstwiring layer on a first insulative substrate and with a second wiringboard having a second wiring layer on a second insulative substrate. Insuch a wiring board, the second wiring board is laminated on the firstwiring board, and the first wiring layer and the second wiring layer areelectrically connected to each other.

In Japanese Laid-Open Patent Publication 2008-300658, a flexible-rigidwiring board is described where a flexible insulative material and arigid insulative material are adhered while being parallel to eachother, and an end portion of the flexible insulative material facing therigid insulative material has a concave-convex portion.

The contents of Japanese Laid-Open Patent Publication Nos. 2003-298234and 2008-300658 are incorporated herein by reference in their entirety.

SUMMARY OF THE INVENTION

A wiring board according to one aspect of the present invention isformed with a first rigid wiring board having an accommodation section,a second rigid wiring board accommodated in the accommodation section,and an insulation layer formed on the first rigid wiring board and thesecond rigid wiring board. In such a wiring board, a conductor of thefirst rigid wiring board and a conductor of the second rigid wiringboard are electrically connected to each other, and at least either aside surface of the second rigid wiring board or a wall surface of theaccommodation section has a concave-convex portion.

A method for manufacturing a wiring board according to another aspect ofthe present invention includes manufacturing a first rigid wiring boardhaving an accommodation section; manufacturing a second rigid wiringboard whose side surface has a concave-convex portion; accommodating thesecond rigid wiring board in the accommodation section; forming aninsulation layer to be formed on the first rigid wiring board and thesecond rigid wiring board; and electrically connecting a conductor ofthe first rigid wiring board and a conductor of the second rigid wiringboard to each other.

A method for manufacturing a wiring board according to yet anotheraspect of the present invention includes manufacturing a first rigidwiring board having an accommodation section whose wall surface has aconcave-convex portion; manufacturing a second rigid wiring board;accommodating the second rigid wiring board in the accommodationsection; forming an insulation layer to be formed on the first rigidwiring board and the second rigid wiring board; and electricallyconnecting a conductor of the first rigid wiring board and a conductorof the second rigid wiring board to each other.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete appreciation of the invention and many of the attendantadvantages thereof will be readily obtained as the same becomes betterunderstood by reference to the following detailed description whenconsidered in connection with the accompanying drawings, wherein:

FIG. 1 is a cross-sectional view of a wiring board according to anembodiment of the present invention;

FIG. 2 is a plan view of a wiring board according to the embodiment ofthe present invention;

FIG. 3A is a view showing a first configuration of a side surface of asecond rigid wiring board and a wall surface of an accommodationsection;

FIG. 3B is a view showing a second configuration of a side surface of asecond rigid wiring board and a wall surface of an accommodationsection;

FIG. 3C is a view showing a third configuration of a side surface of asecond rigid wiring board and a wall surface of an accommodationsection;

FIG. 4A is a cross-sectional view of a first rigid wiring board;

FIG. 4B is a plan view of a first rigid wiring board;

FIG. 5A is a cross-sectional view of a second rigid wiring board;

FIG. 5B is a plan view of a second rigid wiring board;

FIG. 6 is a table showing samples to be used in a drop test and a bendtest;

FIG. 7 is a view showing a sample wiring board having a straightconfiguration;

FIG. 8 is a table showing the results of the drop test;

FIG. 9 is a view to illustrate a bend test;

FIG. 10 is a graph showing the results of the bend test;

FIG. 11A is a view to illustrate a first step for forming a wiring layerof the first rigid wiring board;

FIG. 11B is a view to illustrate a second step for forming a wiringlayer of the first rigid wiring board;

FIG. 11C is a view to illustrate a third step for forming a wiring layerof the first rigid wiring board;

FIG. 11D is a view to illustrate a fourth step for forming a wiringlayer of the first rigid wiring board;

FIG. 12A is a view to illustrate a step for forming an accommodationsection using a die;

FIG. 12B is a view to illustrate a step for forming an accommodationsection using a laser;

FIG. 13 is a view showing an example of a work-size wiring board whichincludes multiple wiring boards;

FIG. 14A is a view to illustrate a first step for forming a first wiringlayer of the second rigid wiring board;

FIG. 14B is a view to illustrate a second step for forming a firstwiring layer of the second rigid wiring board;

FIG. 14C is a view to illustrate a third step for forming a first wiringlayer of the second rigid wiring board;

FIG. 14D is a view to illustrate a fourth step for forming a firstwiring layer of the second rigid wiring board;

FIG. 15A is a view to illustrate a first step for forming a secondwiring layer of the second rigid wiring board;

FIG. 15B is a view to illustrate a second step for forming a secondwiring layer of the second rigid wiring board;

FIG. 15C is a view to illustrate a third step for forming a secondwiring layer of the second rigid wiring board;

FIG. 15D is a view to illustrate a fourth step for forming a secondwiring layer of the second rigid wiring board;

FIG. 16A is a view to illustrate a first step for forming a third wiringlayer of the second rigid wiring board;

FIG. 16B is a view to illustrate a second step for forming a thirdwiring layer of the second rigid wiring board;

FIG. 16C is a view to illustrate a third step for forming a third wiringlayer of the second rigid wiring board;

FIG. 17 is a view to illustrate a step for accommodating a second rigidwiring board in an accommodation section;

FIG. 18A is a view to illustrate a first step for forming insulationlayers and wiring layers on both surfaces of a first rigid wiring boardand a second rigid wiring board;

FIG. 18B is a view to illustrate a second step for forming insulationlayers and wiring layers on both surfaces of a first rigid wiring boardand a second rigid wiring board;

FIG. 18C is a view to illustrate a third step for forming insulationlayers and wiring layers on both surfaces of a first rigid wiring boardand a second rigid wiring board;

FIG. 19A is a view to illustrate a first step for forming externalconnection terminals;

FIG. 19B is a view to illustrate a second step for forming externalconnection terminals;

FIG. 20 is a view showing a first alternative example of a wiring board;

FIG. 21 is a view showing a second alternative example of a wiringboard;

FIG. 22 is a view showing a third alternative example of a wiring board;

FIG. 23 is a view showing a fourth alternative example of a wiringboard;

FIG. 24 is a view showing a fifth alternative example of a wiring board;

FIG. 25 is a view showing a sixth alternative example of a wiring board;

FIG. 26 is a view showing a seventh alternative example of a wiringboard;

FIG. 27 is a view showing an eighth alternative example of a wiringboard;

FIG. 28A is a view showing a ninth alternative example of a wiringboard;

FIG. 28B is a view showing a tenth alternative example of a wiringboard;

FIG. 29 is a view showing an eleventh alternative example of a wiringboard; and

FIG. 30 is a view showing another example of a method for manufacturinga wiring board.

DETAILED DESCRIPTION OF THE EMBODIMENTS

The embodiments will now be described with reference to the accompanyingdrawings, wherein like reference numerals designate corresponding oridentical elements throughout the various drawings.

In the drawings, arrows (Z1, Z2) each indicate a lamination direction ofa wiring board corresponding to a direction along a normal line (or adirection of the thickness of a core substrate) to the main surfaces(upper and lower surfaces) of the wiring board. “Directly on” indicatesa lamination direction. On the other hand, arrows (X1, X2) and (Y1, Y2)each indicate a direction perpendicular to a lamination direction (adirection parallel to the main surfaces of a wiring board). The mainsurfaces of a wiring board are on the X-Y plane. In addition, the sidesurfaces of a wiring board are on the X-Z plane or the Y-Z plane.

In the present embodiment, two main surfaces of a wiring board arereferred to as a first surface (the surface on the arrow-Z1 side) and asecond surface (the surface on the arrow-Z2 side). In a laminationdirection, a side closer to the core (substrates 100, 200) is referredto as a lower layer, and a side farther from the core is referred to asan upper layer. A layer including a conductive pattern that functions aswiring is referred to as a wiring layer. A conductor formed on the wallsurface of a through-hole is referred to as a through-hole conductor.Also, a conductor which is formed in a via hole and electricallyconnects the upper wiring layer and the lower wiring layer to each otheris referred to as an interlayer connection conductor.

As shown in FIG. 1, wiring board 1000 according to the presentembodiment has first rigid wiring board 10, second rigid wiring board20, insulation layers (31, 32), wiring layers (31 a, 32 a),solder-resist layers (41, 42) and external connection terminals (411 a,412 a, 421 a, 422 a). Second rigid wiring board 20 is accommodated inaccommodation section (S1) formed in first rigid wiring board 10.Accommodation section (S1) of the present embodiment is formed as apenetrating hole. Each of wiring board 1000, first rigid wiring board 10and second rigid wiring board 20 is a rigid printed wiring board.

The side surfaces of second rigid wiring board 20 have concave-convexportions as shown in FIG. 2 (plan view). More specifically, the entirecircumference of the side surfaces of second rigid wiring board 20 isshaped zigzag. Also, the wall-surface configuration of accommodationsection (S1) facing the side surface of second rigid wiring board 20 isshaped zigzag corresponding to the side-surface configuration of secondrigid wiring board 20. Namely, a convex portion faces a concave portion,and a concave portion faces a convex portion. Thus, the outercircumference of accommodation section (S1) substantially matches theexternal configuration of second rigid wiring board 20. In the presentembodiment, second rigid wiring board 20 fits with accommodation section(S1). A zigzag configuration indicates that concave portions and convexportions alternate in a series. The numbers of concave portions andconvex portions are not limited specifically, and a concave-convex cyclemay be constant or irregular.

The cycle of a zigzag configuration or the size of concave-convexportions may be irregular or constant. Also, the shape of concave-convexportions is not limited specifically. For example, as shown in FIG. 3A,the concave-convex line may be a line formed with a series ofquadrilaterals (such as rectangular waves or trapezoidal waves).Alternatively, as shown in FIG. 3B, the concave-convex line may be aline formed with arcs (such as sine waves). Yet alternatively, as shownin FIG. 3C, the concave-convex line may be a line formed with a seriesof triangles (such as sawtooth waves). Concave-convex cycle (d1) ispreferred to be, for example, 1.0 mm (the width of a concave and thewidth of a convex are each 0.5 mm, for example). Concave-convexamplitude (d2) is preferred to be 0.5 mm, for example.

As shown in FIG. 4A (cross-sectional view) and FIG. 4B (plan view),first rigid wiring board 10 has substrate 100 to become a core, andwiring layers (100 a, 100 b). Approximate external dimensions of firstrigid wiring board 10 are, for example, width in the X direction 100 mmand width in the Y direction 50 mm.

Substrate 100 is made of epoxy resin, for example. Epoxy resin ispreferred to include a reinforcing material such as glass fabric oraramid fabric, which is then impregnated with resin, for example.Reinforcing materials have smaller thermal expansion coefficients than aprimary material (epoxy resin). As for a reinforcing material, inorganicmaterials are preferred.

On their respective main surfaces of substrate 100, wiring layers (100a, 100 b) made of copper, for example, are formed. Also, through-hole(100 d) is formed in substrate 100. Through-hole conductor (100 c) isformed in through-hole (100 d) by plating copper, for example.Through-hole conductor (100 c) electrically connects wiring layer (100a) and wiring layer (100 b) to each other.

As in FIG. 5A (cross-sectional view) and FIG. 5B (plan view), secondrigid wiring board 20 has substrate 200 to become a core, wiring layers(200 a, 200 b) and (21 a-24 a), insulation layers (21-24), andinterlayer connection conductors (21 b-24 b). Second rigid wiring board20 has smaller external dimensions than first rigid wiring board 10.Approximate external dimensions of second rigid wiring board 20 are, forexample, width in the X direction 40 mm and width in the Y direction 30mm.

Substrate 200 is made of epoxy resin, for example. The same as insubstrate 100, the epoxy resin in substrate 200 is preferred to includea reinforcing material such as glass fabric or aramid fabric, which isthen impregnated with resin, for example.

On their respective main surfaces of substrate 200, wiring layers (200a, 200 b) made of copper, for example, are formed. Also, through-hole(200 d) is formed in substrate 200. Through-hole conductor (200 c) isformed in through-hole (200 d) by plating copper, for example.Through-hole conductor (200 c) electrically connects wiring layer (200a) and wiring layer (200 b) to each other.

Insulation layers (21, 22) are formed on their respective main surfacesof substrate 200. Wiring layer (21 a) is formed on insulation layer 21,and wiring layer (22 a) is formed on insulation layer 22. Wiring layer(200 a) and wiring layer (21 a) are electrically connected to each otherby means of interlayer connection conductor (21 b) formed in insulationlayer 21. Wiring layer (200 b) and wiring layer (22 a) are electricallyconnected to each other by means of interlayer connection conductor (22b) formed in insulation layer 22.

Insulation layer 23 is formed on insulation layer 21, and insulationlayer 24 is formed on insulation layer 22. Wiring layer (23 a) is formedon insulation layer 23, and wiring layer (24 a) is formed on insulationlayer 24. Wiring layer (21 a) and wiring layer (23 a) are electricallyconnected to each other by means of interlayer connection conductor (23b) formed in insulation layer 23. Wiring layer (22 a) and wiring layer(24 a) are electrically connected to each other by means of interlayerconnection conductor (24 b) formed in insulation layer 24.

Wiring layers (21 a-24 a) and interlayer connection conductors (21 b-24b) are made of plated-copper film, for example. Also, insulation layers(21-24) are made of cured prepreg, for example. As for such a prepreg,for example, the following is used: base materials such as glass fabricor aramid fabric are impregnated with resins such as epoxy resin,polyester resin, bismaleimide triazine resin (BT resin), imide resin(polyimide), phenol resin, or allyl polyphenylene ether resin (A-PPEresin).

Configurations and materials for wiring layers (21 a-24 a), interlayerconnection conductors (21 b-24 b) and insulation layers (21-24) are notlimited to those described above, and they may be modified according torequirements or the like. For example, as the material for wiring layers(21 a-24 a) and interlayer connection conductors (21 b-24 b), metalsother than copper may also be used. As the material for insulationlayers (21-24), liquid or film-type thermosetting resins orthermoplastic resins or even RCF (resin coated copper foil) may also beused instead of prepreg. Here, as for thermosetting resins, for example,epoxy resin, imide resin (polyimide), BT resin, allyl polyphenyleneether resin, aramid resin or the like may be used. Also, as forthermoplastic resins, for example, liquid crystal polymer (LCP), PEEKresin, PTFE resin (fluororesin) or the like may be used. Such materialsare preferred to be selected from the viewpoint of insulation,dielectric properties, heat resistance, mechanical features or the like.In addition, additives such as hardening agents, stabilizers, fillers orthe like may be contained in the above resins. Also, wiring layers (21a-24 a) and insulation layers (21-24) may be formed with multiple layers(composite layers) made of different materials.

Interlayer connection conductors (21 b-24 b) of the present embodimentare filled vias in which conductor is filled in via holes. However,interlayer connection conductors (21 b-24 b) are not limited to such,and they may be conformal vias in which conductor is formed on the wallsurfaces of via holes.

First rigid wiring board 10 and second rigid wiring board 20 havesubstantially the same thickness as each other. Also, as describedabove, first rigid wiring board 10 has two wiring layers (100 a, 100 b),and second rigid wiring board 20 has six wiring layers (200 a, 200 b, 21a-24 a). Thus, the number of wiring layers included in the samethickness is greater in second rigid wiring board 20 than in first rigidwiring board 10. The approximate thickness of first rigid wiring board10 and second rigid wiring board 20 is, for example, 560 μm, includingthe conductive patterns on both of their surfaces.

As shown in FIG. 1 (cross-sectional view) and FIG. 2 (plan view), secondrigid wiring board 20 is accommodated in accommodation section (S1)formed in first rigid wiring board 10. Second rigid wiring board 20 isfit into accommodation section (S1). On the first surface and secondsurface of first rigid wiring board 10 and second rigid wiring board 20,insulation layers (31, 32) are laminated. Insulation layer 31 or 32 isformed either on the first surface or the second surface of first rigidwiring board 10 and second rigid wiring board 20. “Accommodated in theaccommodation section” includes cases in which the entire second rigidwiring board is arranged completely in the accommodation section, aswell as cases in which only part of the second rigid wiring board isarranged in the accommodation section. In short, it is sufficient if atleast part of the second rigid wiring board is arranged in theaccommodation section.

Wiring layer (31 a) is formed on insulation layer 31, and wiring layer(32 a) is formed on insulation layer 32. Wiring layer (23 a) and wiringlayer (31 a) are electrically connected to each other by means ofinterlayer connection conductor (31 b) formed in insulation layer 31.Wiring layer (24 a) and wiring layer (32 a) are electrically connectedto each other by means of interlayer connection conductor (32 b) formedin insulation layer 32. In wiring layer (31 a), conductive patterns(311-313) are included, and in wiring layer (32 a), conductive patterns(321-322) are included.

Conductive pattern 322 is electrically connected to wiring layer (100 b)of first rigid wiring board 10 and to wiring layer (24 a) of secondrigid wiring board 20. Accordingly, wiring layer (100 b) (conductor) offirst rigid wiring board 10 and wiring layer (24 a) (conductor) ofsecond rigid wiring board 20 are electrically connected to each other bymeans of via holes formed in insulation layer 32.

Solder-resist layer 41 having opening portions (411 b, 412 b) is formedon insulation layer 31. Also, solder-resist layer 42 having openingportions (421 b, 422 b) is formed on insulation layer 32. Here,solder-resist layers (41, 42) are each made of, for example,photosensitive resin using acrylic-epoxy resin, thermosetting resinmainly containing epoxy resin, UV-curing resin or the like.

Opening portion (411 b) is arranged directly on region (R11) in firstrigid wiring board 10 on the first-surface side. Opening portion (412 b)is arranged directly on region (R12) in second rigid wiring board 20 onthe first-surface side. Opening portion (421 b) is arranged directly onregion (R22) in second rigid wiring board 20 on the second-surface side.Opening portion (422 b) is arranged directly on region (R21) in firstrigid wiring board 10 on the second-surface side.

In opening portions (411 b, 412 b, 421 b, 422 b), external connectionterminals (411 a, 412 a, 421 a, 422 a) made of solder, for example, areformed. External connection terminal (411 a) is electrically connectedto conductive pattern 311. External connection terminal (412 a) iselectrically connected to conductive pattern 312. External connectionterminals (421 a, 422 a) are electrically connected to conductivepattern 322. External connection terminals (411 a, 412 a, 421 a, 422 a)are used for electrical connections, for example, with other wiringboards or electronic components. Wiring board 1000 may be used, forexample, as a circuit substrate for cell phones or the like by beingmounted on other wiring boards using one or both of its surfaces.

On substantially the entire circumferences of (P1, P2) directly on theboundaries between the wall surfaces of accommodation section (S1) andthe side surfaces of second rigid wiring board 20, reinforcing patternsmade of metal film are formed. In the present embodiment, conductivepattern 311 or 313 is formed in (P1) directly on the border portions onthe first-surface side in FIG. 1. Also, conductive pattern 321 or 322 isformed in (P2) directly on the border portions on the second-surfaceside. Here, conductive patterns (311, 322) are used as the wiring forfirst rigid wiring board 10 or second rigid wiring board 20. On theother hand, conductive patterns (313, 321) are solid patterns which areinsulated from the wiring of first rigid wiring board 10 and secondrigid wiring board 20. Such solid patterns are connected to ground, forexample.

In the following, characteristics of wiring board 1000 are described.The inventors conducted drop tests and bend tests on each of wiringboard 1000 and comparative examples.

Such tests were conducted on samples (#1-#4) shown in FIG. 6. Sample #1is a wiring board with a straight configuration and does not havereinforcing patterns. Sample #2 is a wiring board with a zigzagconfiguration and does not have reinforcing patterns. Sample #3 is awiring board with a straight configuration and has reinforcing patterns.Sample #4 is wiring board 1000 of the present embodiment (FIGS. 1, 2).Namely, sample #4 is a wiring board with a zigzag configuration and hasreinforcing patterns. Here, a wiring board with a straight configurationindicates a wiring board such as shown in FIG. 7. A straightconfiguration or a zigzag configuration indicates the configuration ofthe side surfaces of second rigid wiring board 20 and the wall surfacesof accommodation section (S1) (see FIGS. 2, 7). Reinforcing patterns areformed directly on the boundary portions between the wall surfaces ofaccommodation section (S1) and the side surfaces of second rigid wiringboard 20 (for example, conductive pattern 321 or the like shown in FIG.1).

The zigzag configurations in samples (#2, #4) are rectangular waves withconstant cycle (d1) as shown in FIG. 3A previously. The width of theconcave and the width of the convex are each half the cycle.

Drop tests were conducted on samples (#1-#4). More specifically, thesamples were dropped repeatedly, and the number of times dropped wascounted until the samples broke. Such tests were conducted three timeseach on samples (#1-#4). The width and amplitude (d2) (FIG. 3A) of theconcave and convex in the zigzag configuration of samples (#2, #4) usedin the tests are 0.5 mm (cycle (d1)=1.0 mm).

FIG. 8 shows the results of the drop tests. The test results of sample(#1) are three times, four times and seven times; the sample broke at anearly stage in each of the three tests. The test results of samples(#2-#4) show that none broke even after the number of times beingdropped exceeded 200. From the test results, it is assumed that zigzagconfigurations and reinforcing patterns enhance the durability of wiringboards.

Bend tests were conducted on samples (#1-#4). More specifically, asshown in FIG. 9, using three-point bending apparatus 3001 under thecondition that both ends of wiring board 3000 (sample #1-#4) were fixed,pressure exerted on the central portion of wiring board 3000 increaseduntil wiring board 3000 broke. Then, the intensity of the pressure whenthe wiring board broke was measured. The width and amplitude (d2) (FIG.3A) of the concave and convex in the zigzag configuration of samples(#2, #4) used in the tests are 0.5 mm (cycle (d1)=1.0 mm), 1.0 mm (cycle(d1)=2.0 mm) and 1.5 mm (cycle (d1)=3 mm).

FIG. 10 shows the results of the bend tests. Sample #2 was less likelyto break than sample #1, and sample #4 was less likely to break thansample #3. From such test results, it is assumed that zigzagconfigurations enhance the durability of wiring boards. Also, sample #3was less likely to break than sample #1, and sample #4 was less likelyto break than sample #2. From such test results, it is assumed thatreinforcing patterns enhance the durability of wiring boards.

Furthermore, from the results of samples (#2, #4), it can be inferredthat the greater the width and amplitude (d2) of the concave and convex,the greater the durability of the wiring boards. However, it is alsoassumed that durability may not improve notably if the width andamplitude (d2) of the concave and convex are set greater than 0.5 mm. Ifthe width and amplitude (d2) of the concave and convex are set greaterthan that, spaces for mounting components or forming circuits willbecome narrower in first rigid wiring board 10 or second rigid wiringboard 20. Thus, the width and amplitude (d2) of the concave and convexare preferred to be set at 0.5 mm.

As described above, durability may be enhanced in wiring board 1000 ofthe present embodiment. The reasons are assumed to be the following: Byforming the side surfaces of second rigid wiring board 20 and the wallsurfaces of accommodation section (S1) in a zigzag configuration, thecontact areas in first rigid wiring board 10 and second rigid wiringboard 20 will increase, thus suppressing cracks. In addition, since theportions peeled off by cracks may cause failure by protruding onto thesurfaces of a wiring board, suppressing cracks will improveproductivity.

Since flexible materials are not used in wiring board 1000 of thepresent embodiment, first rigid wiring board 10 and second rigid wiringboard 20 may be coated with insulation layers (31, 32). Accordingly, thedurability of wiring board 1000 may be further improved.

Wiring boards (first rigid wiring board 10 and second rigid wiring board20) to be assembled in wiring board 1000 of the present invention areboth rigid wiring boards. Thus, when second rigid wiring board 20 isaccommodated in accommodation section (S1), second rigid wiring board 20may be fixed by friction forces.

In wiring board 1000 of the present invention, since second rigid wiringboard 20 with a greater number of wiring layers than first rigid wiringboard 10 is accommodated in accommodation section (S1), the conductordensity of wiring board 1000 may be increased partially (makinghigher-density wiring).

When manufacturing wiring board 1000 of the present invention, firstrigid wiring board 10 and second rigid wiring board 20 are eachmanufactured first.

When manufacturing first rigid wiring board 10, substrate 1000 havingcopper foils (1001, 1002) on the first surface and the second surface isprepared, as shown in FIG. 11A, for example. As for such startingmaterial, copper-clad laminate may be used, for example. As shown inFIG. 11B, through-hole (100 d) is formed using a drill or a laser, forexample. PN plating (such as chemical copper-plating and copperelectroplating) is performed. Accordingly, as shown in FIG. 11C,conductive films (1003, 1004) are formed on the first surface and thesecond surface of substrate 100, and through-hole conductor (100 c) isformed on the wall surface of through-hole (100 d). Conductive films(1003, 1004) are composite films made by laminating copper foil andcopper-plated coating. Conductive films (1003, 1004) are patterned bypredetermined photo-etching procedures (acid cleansing, resistlamination, exposure and development, etching, film removal and soforth), for example. Accordingly, as shown in FIG. 11D, wiring layers(100 a, 100 b) are formed.

Accommodation section (S1) is formed. During that time, the wallsurfaces of accommodation section (S1) are shaped to be zigzag.

As shown in FIG. 12A, for example, accommodation section (S1) is formedusing quadrilateral cylinder-shaped die 1011. The shape of openingsurface (1011 a) of die 1011 is shaped to be zigzag to correspond to theconfiguration of accommodation section (S1). By pressurizing die 1011twice, for example, accommodation section (S1) is formed in thesubstrate (FIG. 11D), corresponding to the shape of opening surface(1011 a). The material of die 1011 is steel, for example. Theapproximate thickness of die 1011 is 30 mm, for example.

Alternatively, as shown in FIG. 12B, for example, accommodation section(S1) may be formed by laser 1012. Laser 1012 is scanned zigzag tocorrespond to the configuration of accommodation section (S1). Bycutting out the predetermined portion of the substrate (FIG. 11D) usinglaser 1012, accommodation section (S1) shaped to be zigzag may be formedin the substrate.

Accommodation section (S1) is preferred to be formed by die 1011 orlaser 1012, but other methods may be used. For example, accommodationsection (S1) may be formed by a router.

When forming accommodation section (S1), alignment marks (for example,conductive patterns) which can be read by X-rays are arranged in thefour corners of first rigid wiring board 10. Accommodation section (S1)is preferred to be formed at the predetermined position based on suchalignment marks. Also, according to requirements, burrs on the cutsurfaces may be removed.

A work-size wiring board including multiple wiring boards may be used tomanufacture multiple first rigid wiring boards 10 at one time. Forexample, as shown in FIG. 13, multi-piece substrate 50 in which multiplewiring boards 52 are fixed to frame 51 may be used. In such a case,accommodation section (S1) is preferred to be formed based on alignmentmarks 53 (for example, conductive patterns) arranged in four corners ofmulti-piece substrate 50. Accordingly, wiring boards 52 are eachfinished as first rigid wiring board 10.

Accommodation section (S1) is formed through the above steps, and firstrigid wiring board 10 (FIGS. 4A, 4B) having conductors (wiring layers(100 a) and others) is completed.

On the other hand, when manufacturing second rigid wiring board 20, asshown in FIG. 14A, for example, substrate 200 having copper foils (2001,2002) on the first surface and the second surface is prepared. As forthe starting material, copper-clad laminate may be used, for example. Asshown in FIG. 14B, through-hole (200 d) is formed by a drill or a laser,for example. PN plating (such as chemical copper plating and copperelectroplating) is performed. In doing so, as shown in FIG. 14C,conductive films (2003, 2004) are formed on the first surface and secondsurface of substrate 200, and through-hole conductor (200 c) is formedon the wall surface of through-hole (200 d). Conductive films (2003,2004) are composite films made by laminating copper foil andcopper-plated coating.

Conductive films (2003, 2004) are patterned by predeterminedphoto-etching procedures (acid cleansing, resist lamination, exposureand development, etching, film removal and so forth), for example.Accordingly, as shown in FIG. 14D, wiring layers (200 a, 200 b) (firstwiring layers) are formed. Then, the second wiring layers are formedafter an inspection step, a surface-roughening treatment and so forth.

When forming the second wiring layers, as shown in FIG. 15A, forexample, insulation layer 21 having copper foil 2005 is prepared, andinsulation layer 22 having copper foil 2006 is prepared. Insulationlayer 21 is arranged on the first-surface side of substrate 200, andinsulation layer 22 is arranged on the second-surface side of substrate200. Insulation layers (21, 22) are made of prepreg, for example.

Pressure on external-side copper foils (2005, 2006) is exerted using ahydraulic pressing apparatus, for example. In doing so, insulationlayers (21, 22) are pressed, and insulation layers (21, 22) adhere tosubstrate 200.

As shown in FIG. 15B, via hole (2005 a) is formed in insulation layer21, and via hole (2006 a) in insulation layer 22 is formed using alaser, for example. After desmearing, PN plating (such as chemicalcopper plating and copper electroplating) is performed, for example. Indoing so, as shown in FIG. 15C, conductive film 2007 is formed on thefirst surface of insulation layer 21, conductive film 2008 is formed onthe second surface of insulation layer 22, interlayer connectionconductor (21 b) is formed in via hole (2005 a), and interlayerconnection conductor (22 b) is formed in via hole (2006 a). Conductivefilms (2007, 2008) are composite films made by laminating copper foiland copper-plated coating.

Conductive films (2007, 2008) are patterned by predeterminedphoto-etching procedures (acid cleansing, resist lamination, exposureand development, etching, film removal and so forth), for example.Accordingly, as shown in FIG. 15D, wiring layers (21 a, 22 a) (secondwiring layers) are formed. Then, the third wiring layers are formedafter an inspection step, a surface-roughening treatment and so forth.

When forming the third wiring layers, as shown in FIG. 16A, for example,insulation layer 23 having copper foil 2009 is prepared, and insulationlayer 24 having copper foil 2010 is prepared. Insulation layer 23 isarranged on the first-surface side of insulation layer 21, andinsulation layer 24 on the second-surface side of insulation layer 22 isarranged. Insulation layers (23, 24) are made of prepreg, for example.

Pressure is exerted on external-side copper foils (2009, 2010) using ahydraulic pressing apparatus, for example. In doing so, insulationlayers (23, 24) are pressed, insulation layer 21 and insulation layer 23are adhered, and insulation layer 22 and insulation layer 24 areadhered.

As shown in FIG. 16B, via hole (2009 a) is formed in insulation layer23, and via hole (2010 a) is formed in insulation layer 24 using alaser, for example. After desmearing, PN plating (such as chemicalcopper plating and copper electroplating) is performed, for example. Indoing so, as shown in FIG. 16C, conductive film 2011 is formed on thefirst surface of insulation layer 23, conductive film 2012 is formed onthe second surface of insulation layer 24, interlayer connectionconductor (23 b) is formed in via hole (2009 a), and interlayerconnection conductor (24 b) is formed in via hole (2010 a). Conductivefilms (2011, 2012) are composite films made by laminating copper foiland copper-plated coating.

Conductive films (2011, 2012) are patterned by predeterminedphoto-etching procedures (acid cleansing, resist lamination, exposureand development, etching, film removal and so forth), for example.Accordingly, as shown in FIG. 5A previously, wiring layers (23 a, 24 a)(third wiring layers) are formed.

The side surfaces of second rigid wiring board 20 are shaped to bezigzag, using a die or a laser, for example (see FIGS. 12A, 12B). Such azigzag configuration is formed to correspond to the configuration of thewall surfaces of accommodation section (S1). The die used for formingsecond rigid wiring board 20 may be the same as or different from thedie used for first rigid wiring board 10. However, in order to make ahighly accurate fit for both boards, dies to be used exclusively foreach of them are preferred to be prepared.

When forming the side surfaces of second rigid wiring board 20 in azigzag configuration, alignment marks (for example, conductive patterns)that can be readable by X-rays are arranged in four corners of secondrigid wiring board 20, and the configuration is preferred to be formedbased on such alignment marks. Also, according to requirements, burrs onthe cut surfaces may be removed.

By using a work-size wiring board (see FIG. 13) including multiplewiring boards, multiple second rigid wiring boards 20 may bemanufactured at one time.

Through the steps so far, second rigid wiring board 20 (FIGS. 5A, 5B) iscompleted, which has conductors (wiring layers (21 a) and others), whoseside surfaces are zigzag, and whose external dimensions are smaller thanthose of first rigid wiring board 10.

Second rigid wiring board 20 is accommodated in accommodation section(S1) of first rigid wiring board 10. More specifically, as shown in FIG.17, second rigid wiring board 20 is fit into accommodation section (S1).By doing so, second rigid wiring board 20 fits with accommodationsection (S1).

As shown in FIG. 18A, for example, insulation layer 31 having copperfoil 2013 and insulation layer 32 having copper foil 2014 are arrangedon both surfaces of first rigid wiring board 10 and second rigid wiringboard 20. Then, using a hydraulic pressure apparatus, for example,pressure is exerted on the external-side copper foils (2013, 2014). Indoing so, insulation layers (31, 32) are pressed, and first rigid wiringboard 10 and second rigid wiring board 20 are adhered to insulationlayers (31, 32) respectively. At that time, in case slight steps areformed between first rigid wiring board 10 and second rigid wiring board20, a buffer material may be arranged beneath insulation layers (31, 32)to eliminate such steps. Insulation layers (31, 32) are made of prepreg,for example. In addition, as for buffer materials, resin film may beused, for example.

As shown in FIG. 18B, via hole (2013 a) in insulation layer 31 and viahole (2014 a) in insulation layer 32 are formed using a laser, forexample. Furthermore, after desmearing, PN plating (such as chemicalcopper plating and copper electroplating) is performed, for example. Indoing so, conductive film (2015) is formed on the first surface ofinsulation layer 31, conductive film (2016) is formed on the secondsurface of insulation layer 32, interlayer connection conductor (31 b)is formed in via hole (2013 a), and interlayer connection conductor (32b) is formed in via hole (2014 a). Conductive films (2015, 2016) arecomposite films made by laminating copper foil and copper-platedcoating.

As shown in FIG. 18C, for example, conductive films (2015, 2016) arepatterned by predetermined photo-etching procedures (acid cleansing,resist lamination, exposure and development, etching, film removal andso forth). In doing so, wiring layer (31 a) including conductivepatterns (311-313) and wiring layer (32 a) including conductive patterns(321, 322) are formed. Then, wiring layer (100 b) (conductor) on firstrigid wiring board 10 and wiring layer (24 a) (conductor) on secondrigid wiring board 20 are electrically connected to each other by meansof via hole (2014 a) and conductive pattern 322 formed in regard toinsulation layer 32.

As shown in FIG. 19A, for example, solder-resist layer 41 having openingportions (411 b, 412 b) is formed on insulation layer 31, andsolder-resist layer 42 having opening portions (421 b, 422 b) is formedon insulation layer 32, using, for example, screen printing, spraycoating, roll coating or the like. Accordingly, conductive pattern 311is exposed through opening portion (411 b), conductive pattern 312 isexposed in opening portion (412 b), and conductive pattern 322 isexposed through opening portions (421 b, 422 b).

External connection terminals (411 a, 412 a, 421 a, 422 a) are formed inopening portions (411 b, 412 b, 421 b, 422 b). Such external connectionterminals (411 a, 412 a, 421 a, 422 a) may be formed, for example, byapplying solder paste and then curing it through a thermal treatmentsuch as reflow or the like.

Through the steps above, wiring board 1000 (FIGS. 1 and 2) is completed,which has first rigid wiring board 10, second rigid wiring board 20, andinsulation layers (31, 32) formed on first rigid wiring board 10 andsecond rigid wiring board 20, and in which second rigid wiring board 20is accommodated in accommodation section (S1), and conductors of firstrigid wiring board 10 and conductors of second rigid wiring board 20 areelectrically connected to each other.

According to a manufacturing method of the present embodiment, bymanufacturing second rigid wiring board 20 with smaller externaldimensions to be highly integrated, productivity will increase.

In the manufacturing method of the present embodiment, second rigidwiring board 20 with high-density wiring formed through complex steps ismanufactured separately from first rigid wiring board 10. Thus, byinspecting, for example, in a step prior to accommodating second rigidwiring board 20 in first rigid wiring board 10, only a good unit isaccommodated in first rigid wiring board 10. Accordingly, yield rates ofwiring boards 1000 may be improved.

So far, a wiring board and its manufacturing method according to anembodiment of the present invention have been described. However, thepresent invention is not limited to the above embodiment. For example,the present invention may be carried out by being modified as follows.

To suppress cracks or the like, the side surfaces of second rigid wiringboard 20 and the wall surfaces of accommodation section (S1) arepreferred to have a concave-convex configuration on their entirecircumference, but those surfaces are not limited to such. For example,as shown in FIG. 20, even if straight region (RO) is included partially,effects to a certain degree may be expected. However, in such a case aswell, it is preferred that a region of 50% or more of the entirecircumference of second rigid wiring board 20 be shaped zigzag.

The side surfaces of second rigid wiring board 20 and the wall surfacesof accommodation section (S1) are not limited to being perpendicular tothe main surfaces (FIG. 1). For example, as shown in FIG. 21, thesurfaces may be tapered.

Accommodation section (S1) is not limited to a penetrating hole (FIG.1). For example, as shown in FIG. 22, it may be a cavity. However, tomake manufacturing a wiring board easier, and to accommodate furthermultilayered second rigid wiring board 20 in accommodation section (S1),accommodation section (S1) is preferred to be a penetrating hole.

In the above embodiment, second rigid wiring board 20 fits withaccommodation section (S1). However, the present invention is notlimited to such. For example, as shown in FIG. 23, predeterminedclearance may exist between the side surfaces of second rigid wiringboard 20 and the wall surfaces of accommodation section (S1). In such acase, resin (1000 a) contained, for example, in insulation layer 31 or32, is preferred to be filled in gaps between second rigid wiring board20 and accommodation section (51). In doing so, second rigid wiringboard 20 may be secured. In addition, impact on second rigid wiringboard 20 may be mitigated. Resin (1000 a) may be filled in gaps betweensecond rigid wiring board 20 and accommodation section (S1) by beingsqueezed out from insulation layer 31 or 32. However, because of a riskof positional shifting, second rigid wiring board 20 is preferred to befixed prior to filling resin (1000 a), using an adhesive agent or thelike.

Other than those above, the structures of first rigid wiring board 10and second rigid wiring board 20 may be modified within a scope thatdoes not deviate from the gist of the present invention.

As shown in FIG. 24, for example, second rigid wiring board 20 may be awiring board with built-in electronic component 60.

The number of second rigid wiring boards 20 to be accommodated inaccommodation section (S1) is not limited to any specific number. Forexample, as shown in FIG. 25, multiple (such as two) second rigid wiringboards 20 may be accommodated in accommodation section (S1).

The method for connecting first rigid wiring board 10 and second rigidwiring board 20 is not limited specifically. For example, they may beconnected by wire bonding, flip-chip bonding or the like.

First rigid wiring board 10 and second rigid wiring board 20 may besingle-sided wiring boards having conductors (wiring layers) only oneither the upper or the lower surface of a core.

In the above embodiment, the number of wiring layers included in thesame thickness is greater in second rigid wiring board 20 than in firstrigid wiring board 10. However, the present invention is not limited tosuch, and may have any number of wiring layers. The density of existingconductors included in second rigid wiring board 20, however, ispreferred to be higher than the density of existing conductors includedin first rigid wiring board 10. Accordingly, when the number of wiringlayers in first rigid wiring board 10 is the same as the number ofwiring layers in second rigid wiring board 20, as shown in FIG. 26, forexample, the density of wiring patterns is preferred to be higher insecond rigid wiring board 20 than in first rigid wiring board 10.

Insulation layers (31, 32) and solder-resist layers (41, 42) may beformed either on the entire surface or part of the surface of wiringboard 1000. For example, as shown in FIG. 27, insulation layers (31, 32)and solder-resist layers (41, 42) (see FIG. 1) may be formed only inpredetermined region (R100). In such a case as well, insulation layers(31, 32) are formed on first rigid wiring board 10 and second rigidwiring board 20.

The wall surfaces of accommodation section (S1) facing the side surfacesof second rigid wiring board 20 are preferred to have a concave-convexconfiguration corresponding to the concave-convex configuration on theside surfaces of second rigid wiring board 20. However, the presentinvention is not limited to such. For example, as shown in FIG. 28A,only the side surfaces of second rigid wiring board 20 may be shapedzigzag, and the wall surfaces of accommodation section (S1) may beshaped straight. Alternatively, as shown in FIG. 28B, only the wallsurfaces of accommodation section (S1) may be shaped zigzag and the sidesurfaces of second rigid wiring board 20 may be shaped straight.

As shown in FIG. 29, claw receptor (10 a) is formed in first rigidwiring board 10, and lock claw (20 a) is formed in second rigid wiringboard 20. First rigid wiring board 10 and second rigid wiring board 20may be connected by fitting lock claw (20 a) with claw receptor (10 a).Lock claw (20 a) has a trapezoidal shape, widening from second rigidwiring board 20 toward first rigid wiring board 10. Claw receptor (10 a)is a cavity to fit with lock claw (20 a). However, they are not limitedto such. Lock claw (20 a) and its claw receptor (10 a) may be employedin any configuration. Moreover, the lock claw (protruding portion) maybe formed in first rigid wiring board 10, and its claw receptor(recessed portion) may be formed in second rigid wiring board 20.

The contents and the order of the steps in the above embodiment may bemodified freely within a scope that does not deviate from the gist ofthe present invention. Also, unnecessary steps may be omitted accordingto usage requirements or the like.

Instead of the quadrilateral cylindrical shape of die 1011 (FIG. 12A),accommodation section (S1) may be formed using die 1011 which is shapedto have two quadrilateral cylinders joined by shifting from each otheras shown in FIG. 30, for example. In such a case, by pressurizing die1011 once, accommodation section (S1) corresponding to the shape ofopening surface (1011 a) may be formed in a substrate (FIG. 11D).

In the present embodiment, wiring layers (21 a) and others are formed bya subtractive method (a method for patterning by etching). However,instead of a subtractive method, a semi-additive (SAP) method may beemployed. In a semi-additive method, after the entire surfaces of aninsulative substrate are made conductive by electroless plated film(panel plating), a resist is formed and electrolytic plating isperformed in areas without the resist. Then, after the resist isremoved, electroless plated film is patterned by etching.

Obviously, numerous modifications and variations of the presentinvention are possible in light of the above teachings. It is thereforeto be understood that within the scope of the appended claims, theinvention may be practiced otherwise than as specifically describedherein.

1. A wiring board comprising: a first rigid wiring board having anaccommodation portion and a conductor; a second rigid wiring boardaccommodated in the accommodation portion and having a conductorelectrically connected to the conductor of the first rigid wiring board;and an insulation layer formed on the first rigid wiring board and thesecond rigid wiring board, wherein at least one of the second rigidwiring board and the accommodation portion has a concave-convex portionon a side surface of the second rigid wiring board or a wall surface ofthe accommodation portion.
 2. The wiring board according to claim 1,wherein a side surface of the second rigid wiring board has aconcave-convex portion, and a wall surface of the accommodation sectionfacing the side surface of the second rigid wiring board has aconcave-convex portion corresponding to the concave-convex portion onthe side surface of the second rigid wiring board.
 3. The wiring boardaccording to claim 1, wherein a conductor of the first rigid wiringboard and a conductor of the second rigid wiring board are electricallyconnected to each other by means of a via hole formed in the insulationlayer.
 4. The wiring board according to claim 1, wherein the number ofwiring layers included in the same thickness is greater in the secondrigid wiring board than in the first rigid wiring board.
 5. The wiringboard according to claim 1, wherein the density of existing conductorsincluded in the second rigid wiring board is higher than the density ofexisting conductors included in the first rigid wiring board.
 6. Thewiring board according to claim 1, wherein an external connectionterminal is formed in a region directly on the first rigid wiring board,and an external connection terminal is formed in a region directly onthe second rigid wiring board.
 7. The wiring board according to claim 1,wherein a metal film is formed directly on a boundary portion between awall surface of the accommodation section and a side surface of thesecond rigid wiring board.
 8. The wiring board according to claim 1,wherein the second rigid wiring board is a wiring board with a built-incomponent.
 9. A method for manufacturing a wiring board, comprising:forming a first rigid wiring board having an accommodation portion;forming a second rigid wiring board which has a side surface including aconcave-convex portion and which is to be accommodated in theaccommodation portion; accommodating the second rigid wiring board inthe accommodation portion; forming an insulation layer on the firstrigid wiring board and the second rigid wiring board; and electricallyconnecting a conductor of the first rigid wiring board and a conductorof the second rigid wiring board to each other.
 10. The method formanufacturing a wiring board according to claim 9, wherein the formingof the second rigid wiring board comprises forming concave-convex in theside surface of the second rigid wiring board using a laser.
 11. Themethod for manufacturing a wiring board according to claim 9, whereinthe forming of the second rigid wiring board comprises formingconcave-convex in the side surface of the second rigid wiring boardusing a die.
 12. The method for manufacturing a wiring board accordingto claim 9, wherein the forming of the first rigid wiring boardcomprises forming concave-convex in the wall surface of theaccommodation portion using a laser.
 13. The method for manufacturing awiring board according to claim 9, wherein the forming of the firstrigid wiring board comprises forming concave-convex in the wall surfaceof the accommodation portion using a die.
 14. The method formanufacturing a wiring board according to claim 9, wherein theaccommodating of the second rigid wiring board comprises fitting thesecond rigid wiring board within the accommodation portion.
 15. A methodfor manufacturing a wiring board, comprising: forming a first rigidwiring board having an accommodation portion, the accommodation portionhaving a wall surface including a concave-convex portion; forming asecond rigid wiring board which is to be accommodated in theaccommodation portion of the first rigid wiring board; accommodating thesecond rigid wiring board in the accommodation portion; forming aninsulation layer on the first rigid wiring board and the second rigidwiring board; and electrically connecting a conductor of the first rigidwiring board and a conductor of the second rigid wiring board to eachother.